Double backed pile carpets of glass-plastic backings



Oct. 17, 1967 A. T. DILDILIAN 3,347,735

DOUBLE BACKED FILE CARPETS OF GLASS-PLASTIC BACKINGS Filed Nov. 2, 1964Polypropylene Gloss Polypropylene Glass Glass Polypropylene INVENTOR.ARA T. DILDILIAN 4 ATTORNEYS United States Patent 3,347,735 DOUBLEBACKED PILE CARPETS 0F GLASS-PLASTIC BACKINGS Ara T. Dildilian, Fonda,N.Y., assignor to Fiber Glass Industries, Inc., Amsterdam, N.Y., acorporation of New York Filed Nov. 2, 1964, Ser. No. 408,208 4 Claims.(Cl. 161-66) This invention consists in a novel tufted pile fabric,particularly in carpeting composed of a backing through which pile yarnshave been tufted.

A recent improvement in the construction of tufted pile fabrics has beenthe use of a backing formed of woven strands of synthetic plasticribbons or yarns, in place of jute and similar natural yarns theretoforeused. The synthetic yarns are far more uniform and provide for a moreuniform pile pattern. They are also capable of being Woven so closelyspaced together that there are substantially no interstices betweenthem, and accordingly provide better anchorage for the piles.

Synthetic yarns are however somewhat elastic, and also possess a plasticmemory, which makes carpets formed on them relatively unstabledimensionally in that stresses created during the manufacturing processcan relax over a period of time. Heretofore, efforts to overcome stressrelieving relaxation has involved tentering and heat treatmentoperations aimed at removing trapped strains. However, it is stillcommon for such carpeting to either shrink or expand by as much as /2 to'l% under the stresses of manufacturing. Such a carpeting will not bedimensionally stable in service and will require power stretching andtacking down.

I have now discovered that a dimensionally stable carpet having all theadvantages of a synthetic yarn backing can be produced by forming thecarpet initially on a primary backing and then adhesively applying asecondary backing. The two backings in combination provide syntheticstrands which securely hold the pile, and also provide a crossed arrayof fiber glass strands which may also hold the piles and additionallyserve to render the carpet substantially incapable of stretching orshrinkmg.

Preferably, the synthetic strands are polypropylene, but others known tothe art are also satisfactory, as pointed out by Rhodes US. Patent No.3,110,905. The primary backing may be formed entirely of syntheticplastic yarns or ribbons, in which case the secondary backing willconsist entirely of fiber glass yarns.

Alternatively, both the primary and secondary backings may consist ofsynthetic plastic yarns in one direction only, and have fiber glassyarns only in the other direction, and be combined in the carpet so thatthe fiber glass yarns in the secondary backing are at right angles tothe fiber glass yarns in the primary backing.

In this construction it is preferable in the primary backing to have thefiber glass yarns in the warp so that the synthetic yarns which form thefill are not stretched during the weaving operation. The Warp may beentirely of fiber glass yarn or a mixture of fiber glass and othersynthetics.

Suitable yarns from which the primary and secondary backings areconstructed are described in the pending application of Dildilian andNicholas, Serial No. 360,523, filed April 17, 1964 (fiber glass) and inthe above identified Rhodes Patent No. 3,110,905 (synthetic plastic).Both the fiber glass and synthetic strands may be either continuousfilament yarns or staple yarns, or a mixture of the two, and all or partof the synthetic strands may also be in the form of ribbons.

Carpet constructions embodying this invention are shown in theaccompanying drawings in which:

3,347,735 Patented Oct. 17, 1967 backing consisting entirely ofpolypropylene strands. In

a preferred embodiment the strands are in the form of 1080 denierribbons, which may be between li and inch in width of polypropylene.

The piles may be of any conventional natural or synthetic material;their nature does not per se form any part of this invention.

After the piles have been tufted to the backing an adhesive is appliedto the back side and the secondary backing consisting entirely ofinterwoven fiber glass strands is applied. Typically, this fabric willbe made out of 18 warp strands per inch, each having four hundred Kfilaments, and 9 fill strands per inch, each having 800 K filaments.

Any suitable adhesive may be employed to bond the secondary backing,e.g., a latex of polyvinyl acetate, or polybutadiene-styrene.

The construction illustrated in FIG. 2 is made in the same manner asthat illustrated in FIG. I and described above, and differs only in thatthe primary backing is composed of fiber glass warp strands, e.g., l8strands per inch each having 400 K filaments, and polypropylene fillstrands, e.g., 6 double ends per inch, each in the form of a 1080 denierribbon, about A inch wide and 0.002 inch thick, formed of polypropylene.

The secondary backing in the construction of FIG. 2 is formed ofsynthetic warp strands and fiber glass fill strands and is applied withthe fiber glass fill strands running at right angles to the fiber glassWarp strands of the primary backing.

Inasmuch as the dimensional stability of the carpet construction of thisinvention largely depends on the presence of fiber glass strands in bothlongitudinal and transverse directions, it is also contemplated thateach backing may have both synthetic and fiber glass in eitherdirection, so long as one or both together provide fiber glass strandsin both directions. For instance, the primary backing may veryadvantageously consist of warp strands of both fiber glass andpolypropylene, arranged alternately, and polypropylene fill strands, andthe secondary backing may then consist of polypropylene warp strands andfill strands of both fiber glass and polypropylene.

From the foregoing description it will be apparent that this inventionprovides a carpet construction which substantially incorporates theadvantages of a carpet construction featuring a backing of syntheticplastic strands while avoiding substantially entirely thedisadvantageous dimensional instability characteristic of such carpetconstruction.

Having thus disclosed my invention and described in detail preferredembodiments thereof, I claim and desire to secure by Letters Patent:

1. A tufted pile fabric comprising a primary backing woven of strands ofa synthetic plastic in one direction and strands of glass in the otherdirection, pile projections piercing said primary backing, and asecondary backing woven of strands of glass in one direction and strandsof a synthetic plastic in the other direction adhesively secured to theback nonpile side of said primary backing, the fiber glass strands inthe primary backing and secondary backing being at right angles to eachother, said fiber glass strands rendering the fabric substantiallyincapable of stretching or shrinking.

2. A tufted pile fabric comprising a primary backing Woven of strands ofpolyprepylene in one direction and strands of glass in the otherdirection, pile projections piercing said primary backing, and asecondary backing woven of strands of glass in one direction and strandsof polypropylene in the other direction adhesively secured to the backnonpile side, the fiber glass strands in the primary backing andsecondary backing being at right angles to each other, said fiber glassstrands rendering the fabric substantially incapable of stretching orshrink- 3. A tufted pile fabric comprising a primary Woven backinghaving strands of a synthetic plastic in the fill direction and strandsof glass in the warp direction, pile projections piercing said primarybacking, and a secondary Woven backing having strands of glass in thefill direction and strands of a synthetic plastic in the Warp directionadhesively secured to the back nonpile side of the primary backing, thefiber glass strands in the primary backing and secondary backing beingat right angles to each other, said fiber glass strands rendering thefabric substantially incapable of stretching or shrinking.

4. A tufted pile fabric comprising a primary woven backing havingstrands of a synthetic plastic in the fill direction and strands of bothsynthetic plastic and glass in the Warp direction, pile projectionspiercing said primary backing, and a secondary woven backing havingstrands of glass in the fill direction and strands of synthetic plasticin the warp direction adhesively secured to the back nonpile side withthe Warp directions parallel, said fiber glass strands rendering thefabric substantially incapable of stretching or shrinking.

References Cited UNITED STATES PATENTS 2,539,301 1/1951 Foster 1612,983,028 5/1961 Cole 161-67 XR 3,110,905 11/1963 Rhodes 161-62 XR3,238,595 3/1966 Schwartz et a1. 3,309,259 3/1967 Schwartz 16167 MORRISSUSSMAN, Primary Examiner. ALEXANDER WYMAN, Examiner.

R. H. CRISS, Assistant Examiner.

1. A TUFTED PILE FABRIC COMPRISING A PRIMARY BACKING WOVEN OF STRANDS OFA SYNTHETIC PLASTIC IN ONE DIRECTION AND STRANDS OF GLASS IN THE OTHERDIRECTION, PILE PROJECTIONS PIERCING SAID PRIMARY BACKING, AND ASECONDARY BACKING WOVEN OF STRANDS OF GLASS IN ONE DIRECTION AND STRANDSOF A SYNTHETIC PLASTIC IN THE OTHER DIRECTION ADHESIVELY SECURED TO THEBACK NONPILE SIDE OF SAID PRIMARY BACKING, THE FIBER GLASS STRANDS INTHE PRIMARY BACKING AND SECONDARY BACKING BEING AT RIGHT ANGLES TO EACHOTHER, SAID FIBER GLASS STRANDS RENDERING THE FABRIC SUBSTANTIALLYINCAPABLE OF STRETCHING OR SHRINKING.